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Porsche & MAHLE Produces 3D Printed Aluminum Pistons

Auto News - Published on Tue, 14 Jul 2020

Image Source: Mahle Trumpf Porsche 3D Printing Aluminium Pistons
In cooperation with its partners Mahle and Trumpf, Porsche is establishing a new milestone in the use of additive manufacturing processes for highly-stressed drive components. 3D printing technology is already used at the sports car manufacturer in prototype construction, manufacturing spare parts for classic sports cars as well as in other areas. For the first time, the pistons for the high-performance engine of the 911 flagship model, the GT2 RS, are now being produced with a 3D printer. 3D printing allows the pistons to be manufactured with a structure that is optimised for the loads acting on the pistons. As a result, the pistons from the advance development project weigh ten percent less than the forged series production pistons. They also have an integrated and closed cooling duct in the piston crown that could not have been produced by conventional methods.

There are a number of different technologies for 3D printing. All are based on the principle that the components are built up layer by layer without the need to previously manufacture a special tool or mould. Practically any geometric shape can therefore be realised. The printer can be fed with the design data directly from the computer. Additive manufacturing processes are thus ideal for producing structures that have been designed and optimised by means of artificial intelligence.

The pistons of the 911 GT2 RS were manufactured from high-purity metal powder using the laser metal fusion process (LMF). Here, a laser beam heats and melts the powder surface corresponding to the part contour. Porsche initiated the joint project together with cooperation partners Mahle and Trumpf. The quality and performance capability of the components were validated using measurement technology from Zeiss.

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Posted By : Yogender Pancholi on Tue, 14 Jul 2020
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